Power distribution panel with modular elements

ABSTRACT

A power distribution panel having circuit elements such as KTK and GMT fuses removably mounted to a unit housing by means of module members, thereby allowing for ease of customization of the circuit elements of the power distribution panel.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of application Ser. No. 11/489,743,filed Jul. 18, 2006, now Pat. No. 7,304,834, which is a continuation ofapplication Ser. No. 11/091,862, filed Mar. 28, 2005, now U.S. Pat. No.7,126,803, which is a continuation of application Ser. No. 10/194,689,filed Jul. 12, 2002, now U.S. Pat. No. 6,873,510, which is acontinuation of application Ser. No. 09/541,340, filed Apr. 3, 2000, nowU.S. Pat. No. 6,456,203 B1, which applications and now issued patent areincorporated herein by reference.

FIELD OF THE INVENTION

The present invention relates to a power distribution panel with circuitelement modules.

BACKGROUND OF THE INVENTION

Electrical circuit panels such as power distribution panels typicallyinclude a number of different circuit elements such as fuse holders andfuses, circuit breakers, input and output connectors, and alarm signalLEDs. For safety and other reasons, the electrical circuits of powerdistribution panels are enclosed within a housing structure. Therefore,the circuit elements listed above have typically been inserted intoholes which have been pre-cut or pre-punched into the housing structure,usually on a front or back panel of the housing structure. These priorcircuit panels are fixed in that once the holes are formed in thehousing, the type and arrangement of the components is limited.

In order to manufacture different fixed circuit panels of the priorsystems, a circuit panel manufacturer would punch out different patternsof holes in the front or back panels of the housing structure in orderto accommodate different arrangements of circuit elements. Significantretooling time and costs are involved for offering different fixedpanels. Assembly of the circuit elements is also difficult when theelements are inserted through the holes. There is a need for furthercircuit panels which allow for more efficient manufacture and use.

SUMMARY OF THE INVENTION

The present invention is an improved circuit panel such as a powerdistribution panel constructed with circuit element modules. The circuitelement modules eliminate the need for punching patterns of speciallyshaped holes into a front and/or back panel of the housing structure foreach element. The circuit elements are disposed on modular members ofstandardized dimensions which allow the elements to be coupled to thehousing structure in one of a variety of selected configurations withoutthe need to customize a hole pattern in a front panel of the housingstructure. Eliminating the discrete hole punching increases the ease ofproducing variable product line or customized circuit panels and resultsin quicker delivery to the customer.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is an exploded view of one preferred embodiment of a powerdistribution panel with circuit element modules according to the presentinvention.

FIG. 2 is a top view of the preferred embodiment of the powerdistribution panel of FIG. 1.

FIG. 3 is a front view of the preferred embodiment of the powerdistribution panel of FIG. 1.

FIG. 4 is a further exploded view of the power distribution panel ofFIG. 1.

FIG. 5 is a cross-sectional side view defined by line A-A in FIG. 2.

FIG. 6 is a cross-sectional side view defined by line B-B in FIG. 2.

FIG. 7 is a front view of one embodiment of a KTK/KLM-type fuse holdermodule with KTK/KLM-type fuse configured according to the presentinvention.

FIG. 8 is a side view of the KTK fuse module of FIG. 7.

FIG. 9 is a bottom view of the KTK fuse module of FIG. 7.

FIG. 10 is a rear view of the KTK fuse module of FIG. 7.

FIG. 11 is a front view of one embodiment of a GMT-type fuse holdermodule with four GMT fuse holder locations and fuses configuredaccording to the present invention.

FIG. 12 is a side view of the four position GMT fuse module of FIG. 11.

FIG. 13 is a bottom view of the four position GMT fuse module of FIG.11.

FIG. 14 is a rear view of the four position GMT fuse module of FIG. 11.

FIG. 15 is a front view of one embodiment of a power on LED indicatormodule configured according to the present invention.

FIG. 16 is a side view of the power on LED indicator module of FIG. 15.

FIG. 17 is a bottom view of the power on LED indicator module of FIG.15.

FIG. 18 is a rear view of the power on LED indicator module of FIG. 15.

FIG. 19 is a front view of a KTK/KLM-type output connector module withKTK output connectors as it would appear if viewing the back of thepower distribution panel.

FIG. 20 is a side view of the KTK output connectors of FIG. 19.

FIG. 21 is a rear view of the KTK output connector module of FIG. 19.

FIG. 22 is a front view of a GMT-type output connector module with GMToutput connectors as it would appear if viewing the back of the powerdistribution panel.

FIG. 23 is a side view of the GMT output connector module of FIG. 22.

FIG. 24 is a rear view of the GMT output connector module of FIG. 22.

FIG. 25 is a front view of an alarm output module as it would appear ifviewing the back of the power distribution panel.

FIG. 26 is a side view of the alarm output module of FIG. 25.

FIG. 27 is a rear view of the alarm output module of FIG. 25.

FIGS. 28A and B are circuit diagrams of a circuit used in a powerdistribution panel of the present invention with KTK fuses.

FIG. 29 is a circuit diagram of a circuit used in a power distributionpanel of the present invention with GMT fuses.

FIG. 30 is a circuit diagram of an alarm board circuit used in a powerdistribution panel of the present invention.

FIG. 31 is a rear view of the preferred embodiment of the powerdistribution panel of FIG. 1 with the protective panel removed.

FIG. 32 is a circuit breaker module according to the present invention.

FIG. 33 is one preferred embodiment of a total front access powerdistribution panel.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

A power distribution panel is a circuit panel which channels power froma supply line input power to a number of different pieces of equipment.Therefore, a power distribution panel typically has one or more powerinput connections and an array of output connections to which the piecesof equipment to be supplied with power are connected. The typical powerdistribution panel also comprises an array of fuse locations, normallyone fuse location for each output connection. Alternatively, or incombination, circuit protection may be provided by circuit breakers.This specification and accompanying drawings relate to preferredembodiments of a power distribution panel primarily with fuse modulesbut it is to be understood that the present invention is applicable toother types of circuit panels using other circuit element modules suchas circuit breaker modules, other circuit protection modules, or othercircuit element modules with different functions altogether.

As shown in the preferred embodiment of FIGS. 1-31, a power distributionpanel 1 is shown having a unit housing 2 with a top panel 3, a bottompanel 5, and two side panels 7 and 9. The top, bottom and two sidepanels define a front end 11 of the unit housing 2. The unit housing 2also includes a back panel or portion 13. The back portion 13 is coupledto the top and bottom panels 3 and 5 of the unit housing to form a backend of the unit housing. In the preferred embodiment, the unit housing 2is made of sheet metal or molded plastic. Mounting brackets 4 areprovided along the side for mounting panel 1 to a rack, frame or otherequipment supporting structure.

The panel 1 of the present invention presents a configurable housing orchassis that allows use of the common chassis with various modularcomponents that define the circuit functionality of the panel. Thepreferred panel 1 includes modular constructions for the fuse or othercircuit protection components, and modular constructions for the poweroutput connectors, status and alarm indicators, and alarm signalconnectors.

The present invention couples circuit element modules 15 onto the frontend 11 of the fuse panel. Each circuit element module 15 preferablyincludes a circuit element mounted onto a generally C-shaped modulemember 17 having upper and lower flange surfaces 19 and 20 which areconnected by a middle front surface 21. The circuit element 15 may be,for example, a KTK/KLM-type fuse holder location 24 for a KTK fuse 25 asshown in FIGS. 7-10, an array of GMT-type fuse holder locations 26 forGMT fuses 27 as shown in FIGS. 11-14, a power on indicator LED 29 asshown in FIGS. 15-18, a circuit breaker 30 as shown in FIG. 32, TPS-typefuses, or TPA-type fuses, or any other circuit protector element orother circuit element.

The module members 17 are configured to fit the front end of the unithousing. The module members 17 may be made from bent and cut sheetmetal, or from plastic. The module members 17 are made in standardizedsizes and shapes, allowing assembly of the fuse panel to easily andefficiently vary a product line or customize the configuration in aparticular manner. The manufacturer or the customer may choose thenumber and type of fuses, circuit breakers, and other circuit elementsdesired up to the capacity of the power distribution panel which isgoverned by the width and height of the panel. In some applications, thecircuit elements in the power distribution panel can be changed as theuser's needs change or as elements need replacement or upgrading.

As shown in FIGS. 5 and 6, the top panel 3 may be recessed at recess 28to receive the upper flange surfaces 19 of the module members 17,presenting a generally planar top surface of the panel 1. In a similarmanner, the lower flange surfaces 20 of the module members 17 may berecessed at recess 32 to receive the bottom panel 5, presenting agenerally planar bottom surface of the panel 1.

The top panel 3 and the upper flange surfaces 19 of the module members17 define fastener holes or perforations 31 for coupling the circuitelement modules 15 to the panel 1. Additionally, the bottom panel 5 andthe lower flange surfaces 20 of the module members 17 may definefastener perforations 31. Due to the C-shaped configuration of themodule members the circuit element modules are coupled to the panel 1without devoting space on the middle front surfaces 21 of the modulemembers 17 to fastener perforations and fasteners. By placing thefasteners and fastener perforations 31 on upper and lower flangesurfaces 19 and 20 and not on the middle front surface 21, more circuitelement modules 15 may be fitted into the same size panel. Fastenerperforations 31 on top and bottom panels 3, 5 are positioned in desiredpatterns, preferably repeating or equally spaced patterns to facilitateincreased versatility of panel 1. The repeating patterns may besequential, or mirror images. Some perforations may not be used for eachpanel 1, depending on the length of the modules.

The fastener perforations 31 in the upper and lower flange surfaces 19,20 of the module members 17 are positioned not to have their axesconcentric. If the single fastener perforations 31 were along concentricaxes, the circuit element modules would tend to pivot around an axisdefined by the fastener perforations. By positioning the fastenerperforations 31 on the upper and lower flange surfaces 19 and 20 onseparate vertical axes, the circuit element modules 15 are more stableand will not pivot. By more securely mounting the modules to limitrotation, a safer module and panel results since moveable modules maypresent electrical hazards. In FIGS. 9, 13 and 17 it can be seen thatthe fastener perforations 31 are off-center and therefore not alignedco-axially with the fastener perforations on the upper flange surface19. The fastener perforation 31 in the lower flange surface 20 of themodule members 17 may alternatively be sized to fit over a positioningpeg disposed on the bottom panel 5 of the unit housing to prevent themodules from pivoting.

Each circuit element module 15 is sized in width to be a multiple ofsome unit length. For example, if the unit length were 1.5 inches, thecircuit element modules could be 1.5, 3, 4.5, 6, or 7.5 inches wide orwider, up to a maximum width of the panel. A circuit element module thatis 3 inches wide may be replaced by two circuit element modules that areeach 1.5 inches wide. Therefore, although the GMT fuse modules shown inFIGS. 1 and 11-14, have arrays of four GMT fuse holder locationspositioned on module members 1.5 inches wide, it is to be understoodthat larger arrays of fuse holders such as 10 fuse holder arrays couldbe used with the present invention simply by placing the larger arrayson module members that are, in the preferred embodiment, multiples of1.5 inches wide, for example, 3 or 4.5 inches wide. As an alternative,the unit length may be 0.5 inches, and the modules may be multiples of0.5 inches, with no module actually 0.5 inches in length.

Referring now to FIG. 4, the back portion 13 is coupled to the top panel3 by fastener tabs 33 which may be recessed underneath the top panel 3,presenting a generally planar top surface of the panel 1 (see FIGS. 5and 6). The fastener tabs 33 and top panel define fastener perforations31 for coupling the back portion 13 to the top panel 3. The bottom panelis also coupled to the back portion 13. The bottom panel 5 may berecessed to receive the back portion 13, presenting a generally planarbottom surface of the panel 1 (see FIGS. 5 and 6).

Not only are the circuit elements modularized, but power input andoutput connectors may also be modularized. Typically, the power inputand output connectors are placed in the back portion 13 of the panel asshown in FIG. 1, but they may also be placed at the front end as shownin FIG. 33. The input and output connectors may be modularized intoconnector modules 35 by placing arrays of connector locations ontomodule plates 37. The module plates 37 and connector arrays areconfigured to fit a window 14 formed in the back portion 13. The outputconnector arrays may be, for example, KTK/KLM-type output connectors 39as shown in FIGS. 19-21, or GMT-type output connectors 41 as shown inFIGS. 22-24. The module plates may be L-shaped, C-shaped or other asdesired for mounting to the panel 1. The output connectors 39 and 41 maybe screw-down barrier terminal strip type connectors or a set-screwbarrel terminal strip or even ring terminals, or other connector types.An alarm output connector module 43 may also be included as shown inFIGS. 25-27. The alarm output connectors 43 may be connected to remotedevices to signal when a power or fuse (or other circuit protectionelement) failure has occurred.

The back portion 13 is also configured with power input windows 12 toreceive power input connectors 47. The power input connectors 47 areconfigured to accept electrical power supply lines. The power inputconnectors 47 may be configured as two hole compression lug-stud typeconnections or set screw barrel connections or other connectors known inthe art. A protective rear panel 57 is used as a safety precaution tocover the power input connectors 47 and the output connectors 39, 41 and43.

FIGS. 7-10 show a KTK/KLM-type fuse holder module 15′ configuredaccording to the present invention. The lower flange surface 20 isextended to accommodate a fuse alarm board 45 which may be configured toconnect the KTK/KLM-type fuse 25 and an alarm LED 49. FIGS. 11-14 show aGMT fuse holder module 15″ also configured with an alarm LED. GMT module15″ includes designation pin holders 22 in a vertical line for holding adesignation pin (peg) 23 for each fuse holder to provide indicia as tothe fuse type inserted into the fuse holder location. A preferredlocation for LED's 49 is along a lower portion of panel 1. Such afeature is advantageous because panel 1 is typically located higher inthe rack, so viewing of lower LED's 49 is more convenient to the user.FIGS. 15-18 show a power on LED module 29 for signaling when the panelis receiving power. The panel may be configured as shown in FIG. 31 toreceive dual power inputs, therefore the power on LED module shown inFIGS. 15-18 may include a power on indicator LED 51 for each powerinput.

The modules 15′ and 15″ are generally C-shaped members which define acircuit holder in front section 21. Front section 21 is formed toinclude a hole for receipt of the desired fuse holder or other circuitelement to be mounted thereto by fasteners or other mounting mechanisms.A blank module 15′″ is shown in panel 1 at the left end. LED module 29and blank module 15′″ are also C-shaped.

The power input connectors 47 shown in FIG. 31 are connected to thefuses of the circuit element modules 15 and thereby to the power outputconnectors by means of an electrical circuit. The circuit will varydepending on the configuration of the circuit element modules 15 and theoutput connector modules 35 selected and may include a panel alarm board53. The preferred circuit links the power input to the power outputconnectors through the fuse or other circuit protecting components. Thepreferred circuit also provides alarm and status signals to the user,such as “power on,” and “fuse blown.” FIGS. 28A and B show a typicalelectrical circuit for connecting an array of KTK fuses to the powerinput connectors 47, the KTK alarm boards 45, and KTK output connectors39. FIG. 29 shows a typical electrical circuit for connecting an arrayof GMT fuses to the power input connectors 47, the GMT output connectors41, the alarm LED 49 on the GMT module, and the panel alarm board 53.FIG. 30 shows a typical electrical circuit connecting the alarm board 53to the power input connections 47 and power on indicator LED 51.

A manufacturer of a circuit panel according to the present invention mayalso manufacture and supply to the panel user, circuit element modules15 which have been pre-wired for installation. Pre-wired modules alsosimplify assembly by the manufacturer. Circuit element modules 15 can beelectrically connected to appropriate wires with connectorized ends bythe manufacturer, to facilitate easy assembly. See for example leads 61in FIG. 8.

As described above the power distribution panel is modularized both inthat the circuit elements such as fuses and circuit breakers aremodularized, and in that the output connectors are modularized. As shownin FIG. 33, a total front access power distribution panel 1′ can beconstructed according to the present invention which would provide formodular circuit elements 15′ and 15″ as well as output connectors 39 and41 and alarm connectors 43 on the front. An appropriately configuredfront housing 66 includes structure for attaching to each of themodules, whether they are C-shaped or planar shaped.

The present invention may include ventilation slots 55 in the top panelof the unit housing. Alternatively or in combination the top panel maycomprise a heat sink, such as described in U.S. application Ser. No.09/527,897, filed Mar. 20, 2000, and the disclosure of which is herebyincorporated by reference.

Although not required, in the preferred embodiment it should be notedthat the blanks 15′″ are shorter in length than modules 15′15″. Blanks15′″ are equal in length to LED module 29. If longer modules 15 areused, multiple fasteners may be employed, such as through holes 31 a inthe case of a 3 unit fuse module. Holes 31 a are not used in theillustrated panel 1 with the various illustrated modules 15, 29.

The panel 1 of the present invention includes a configurable front end,and possibly a configurable back end for the various circuit modules,alarm/signal modules, and the connector modules for configuring thepanel to have the desired functions. Such a construction allows forefficient inventory management, and more timely delivery of variedpanels to customers. For example, the user can specify one or more ofthe following: front/rear access; input power connector type;fuse/circuit breaker types and numbers, output power connector type(s);alarm signal connector type(s); and the alarm signal type(s). Bymaintaining one or more styles of chassis, and an inventory ofcomponents, the different panels can be conveniently assembled.

The above specification, examples and data provide a description of theinvention. Since many embodiments of the invention can be made withoutdeparting from the spirit and scope of the invention, the inventionresides in the claims hereinafter appended.

1. A method of configuring a power distribution panel, the methodcomprising: mounting a chassis for forming a power distribution panel toa support structure, the chassis including a housing having a back, top,bottom, and two opposed side surfaces, the housing defining an openfront end for receiving circuit element modules, the housing alsodefining an interior of the power distribution panel, the open front enddefined by front parallel edges spaced apart and facing one another;mounting a circuit element module to the power distribution panel, thecircuit element module including a circuit element and a module memberhaving upper and lower flange surfaces connected by a front surface, theupper and lower flange surfaces being generally perpendicular to thefront surface and extending from the front surface in the same directionand opposing one another, the upper surface defining a fastener hole forcoupling the circuit element module to the open front end of thechassis, the front surface defining a location for receiving a circuitelement; and coupling the circuit element to circuitry incorporated inthe power distribution panel.
 2. The method of claim 1, furthercomprising installing a circuit element into the circuit element module.3. The method of claim 1, wherein the circuit element is a fuse.
 4. Themethod of claim 1, wherein the circuit element is a circuit breaker. 5.The method of claim 1, wherein the circuit element module includes anLED indicator received at an alarm hole for receiving the LED indicator,the alarm hole located in the front surface of the circuit elementmodule.
 6. The method of claim 1, wherein coupling the circuit elementcomprises coupling a connectorized end of the circuit element to aconnector incorporated in circuitry of the power distribution panel. 7.The method of claim 1, further comprising connecting a power inputmodule to the chassis.
 8. The method of claim 7, wherein connecting apower input module to the panel comprises screwing the power inputmodule to a back surface of the chassis.
 9. The method of claim 1,further comprising connecting a power output module to the chassis, thepower output module including an array of output connectors.
 10. Themethod of claim 9, wherein connecting a power output module to the panelcomprises screwing the power output module to a back surface of thechassis.
 11. The method of claim 1, further comprising: disconnectingthe circuit element module from the circuitry; removing the circuitelement module from the power distribution panel; mounting a secondcircuit element module to the power distribution panel in the positionof the circuit element module; and connecting the second circuit elementmodule to the circuitry; wherein the second circuit element moduleincludes a circuit protection device different from the circuitprotection device of the circuit protection module.
 12. A circuitelement module for use in a power distribution panel, the circuitelement module comprising: a circuit element holder location; and amodule member having upper and lower flange surfaces connected by afront surface, the upper surface defining a fastener hole for couplingthe fuse module to a fuse panel, the front surface defining a circuitelement hole for receiving a circuit element; the lower flange surfacedefining a second fastener hole displaced from an axis defined by theupper flange surface's fastener hold, the axis being perpendicular tothe upper and lower flange surfaces, the lower flange surface beingrecessed to fit a power distribution panel.
 13. The circuit elementmodule of claim 12, wherein the circuit element includes at least onefuse.
 14. The circuit element module of claim 12, wherein the circuitelement is a circuit breaker.
 15. The circuit element module of claim12, further comprising an LED indicator received in the front surface ofthe module member.
 16. A power distribution panel comprising: a housinghaving a back, top, bottom, and two side surfaces, the housing definingan open end opposite the back surface for receiving circuit elementmodules, the housing also defining an interior of the power distributionpanel; a plurality of circuit element modules coupled to the housing atthe open end of the housing, wherein each circuit element nodulecomprises a circuit element disposed on a module member, the modulemembers being configured to fit adjacent to the open end of the housing,the modules cooperating to close the open end, and further, wherein theplurality of circuit element modules includes at least one power inputconnector module, at least one power output connector array module, anda plurality of circuit component protection modules; and an electricalcircuit disposed within the interior of the power distribution panel,the electrical circuit electrically connecting the power input connectormodule and the power output connector array module to the circuitelements of the other circuit element modules.
 17. The powerdistribution panel of claim 16, wherein the module members are C-shapedhaving upper and lower flange surfaces, the upper flange surfacedefining a first fastener hole for securing the modular member to thetop surface of the housing of the power distribution panel, the lowerflange surface defining a second fastener hole.
 18. The powerdistribution panel of claim 16, wherein at least one of the plurality ofcircuit component protection modules includes a circuit protectioncomponent.
 19. The power distribution panel of claim 18, wherein thecircuit protection component is an array of fuse elements.
 20. The powerdistribution panel of claim 19, wherein the array of fuse elementscontains a number of fuses corresponding to a number of connectors ofthe power output connector array module.
 21. A power distribution panelcomprising: a housing having a back, top, bottom, and two side surfaces,the back surface configured with a power input connector and an array ofpower output connectors, the housing defining an open end opposite theback surface for receiving circuit element modules, the housing alsodefining an interior of the power distribution panel; a plurality ofcircuit element modules coupled to the housing at the open end of thehousing, wherein each circuit element module comprises a circuit elementdisposed on a module member, the module members being configured to fitadjacent to the open end of the housing, the modules cooperating toclose the open end, and further, wherein the plurality of circuitelement modules includes a plurality of circuit component protectionmodules; and an electrical circuit disposed within the interior of thepower distribution panel, the electrical circuit electrically connectingthe power input connector module and the power output connector arraymodule to the circuit elements of the other circuit element modules. 22.The power distribution panel of claim 21, wherein the circuit componentprotection modules span from the top to the bottom of the open end lfthe housing, closing at least a portion of the open front end.
 23. Thepower distribution panel of claim 21, wherein the circuit elements areselected from the group consisting of: a circuit breaker; a fuse; and afuse array.
 24. A chassis for forming a power distribution panelcomprising: a housing having a back, top, bottom, and two opposed sidesurfaces, the housing defining an open end opposite the back surface forreceiving circuit element modules, the housing also defining an interiorof the power distribution panel; the open front end defined by frontparallel edges spaced apart and facing one another, each edge includinga repeating pattern of fastener holes; and an electrical circuitdisposed within the interior of the chassis, the electrical circuitelectrically configurable to connect a power input connector and a poweroutput connector array to circuit elements of circuit element modulesmounted to the open front end.
 25. The chassis of claim 24, wherein atleast one circuit element module is mounted to the open end.